Vehicle Integrated Propulsion Research (VIPR) Gas …...Engine Test Program 3 • VIPR is a series of ground-based on-wing engine demonstrations to mature aircraft engine health management

National Aeronautics and Space Administration

www.nasa.gov 1

Vehicle Integrated Propulsion

Research (VIPR) Gas Path Diagnostics

and Volcanic Ash Ingestion Test

Results

Donald L. Simon & Jeff Csank

NASA Glenn Research Center

Aidan Rinehart

Vantage Partners, LLC

5th NASA GRC Propulsion Control and Diagnostics (PCD) Workshop

September 16 - 17, 2015

Cleveland, Ohio


www.nasa.gov

Outline

• Vehicle Integrated Propulsion Research (VIPR) Overview

• VIPR3 Gas Path Diagnostic (GPD) testing

– Model-Based Gas Path Diagnostic Architecture

– Bleed fault diagnostic results

• VIPR3 Volcanic Ash Environment (VAE) testing

– VAE test overview

• Summary


www.nasa.gov

Vehicle Integrated Propulsion (VIPR)

Engine Test Program

3

• VIPR is a series of ground-based on-wing

engine demonstrations to mature aircraft

engine health management technologies

• Test vehicle is a U.S. Air Force C-17 aircraft

equipped with Pratt & Whitney F117 engines

• VIPR partners include NASA, U.S. Air Force

and other external organizations

• VIPR test schedule– VIPR1 (2011)

– VIPR2 (2013)

– VIPR3 (2015)

• VIPR3 testing covered in this presentation:– Gas Path Diagnostics (GPD): A series of nominal

and faulted engine test cases

– Volcanic Ash Environment (VAE): Low

concentration engine ash ingestion testing

Pratt & Whitney F117 Turbofan Engine

Boeing C-17 Globemaster III


www.nasa.gov

VIPR3 Gas Path Diagnostics

Test Architecture

4

Data acquired from

aircraft bill-of-material

sensors and advanced

EHM sensors

NASA Data

Acquisition Pallet

Bleed faults

manually inserted

Real-time

laptop

displays

EHM sensor data

acquisition and signal

processing

On engine

In aircraft cargo bay

Bleed valve

control boxes

used to manually

insert station 2.5

and 14th stage

bleed valve faults


www.nasa.gov

Model-Based Gas Path Diagnostic Architecture

5

Actuator Commands and

Sensor Measurements

Fault diagnostics

Real-time adaptive

performance model

(RTAPM)Aircraft Engine

Periodic model tuning

parameter updates

+

-

u

y

y

Estimated

performance

parameters

y

N1y~Performance

baseline model (PBM)

• Real-time adaptive performance model (RTAPM): Self-tuning Kalman filter design

which applies NASA-developed optimal tuner selection methodology. Provides

estimates of unmeasured engine performance parameters.

• Performance baseline model (PBM): Serves as a baseline of engine performance.

• Fault diagnostics: Analyzes residuals between sensed engine outputs and PBM

estimated outputs for fault detection and isolation purposes.


www.nasa.gov

VIPR3 GPD Bleed Fault Testing

6

• VIPR3 GPD Bleed Fault Scenarios

o EHM Baseline Engine Run

o 2.5 Failed full-open baseline

o 2.5 Failed full-open at steady-state

o 2.5 Failed full-open during ramp accel

o 2.5 Failed full-open during snap accel

o 14th Failed full-open baseline

o 14th Failed full-open at steady-state

o 14th Failed full-open during ramp accel

o 14th Failed full-open during snap accel

Transient Run

Time

PowerSetting

Valve failed open Return to

EEC Control

Valve failed open

Return to EEC

Control


www.nasa.gov

BLD14 Failed at Steady-State

yi

WS

SR

0 100 200 300 400 500 600 7000: No fault1: FAN 2: LPC 3: HPC 4: HPT 5: LPT 6: B25 7: VSV 8: B14

Dia

gnosed F

ault

Time (sec)

Engine measurement

Re-trimmed PBM

WSSR

Anomaly detection threshold


www.nasa.gov

BLD14 Failed During Snap Accel

yi

WS

SR

0 500 1000 1500 2000 25000: No fault1: FAN 2: LPC 3: HPC 4: HPT 5: LPT 6: B25 7: VSV 8: B14

Dia

gnosed F

ault

Time (sec)

Engine measurement

Re-trimmed PBM

WSSR



www.nasa.gov

BLD25 Failed at Steady-State

yi

WS

SR

0 100 200 300 400 500 600 700 8000: No fault1: FAN 2: LPC 3: HPC 4: HPT 5: LPT 6: B25 7: VSV 8: B14

Dia

gnosed F

ault

Time (sec)

Engine measurement

Re-trimmed PBM

WSSR



www.nasa.gov

BLD25 Failed During Snap Accel

yi

WS

SR

0 200 400 600 800 1000 1200 1400 16000: No fault1: FAN 2: LPC 3: HPC 4: HPT 5: LPT 6: B25 7: VSV 8: B14

Dia

gnosed F

ault

Time (sec)

Engine measurement

Re-trimmed PBM

WSSR



www.nasa.gov

VIPR3 Volcanic Ash Environment (VAE) Testing

11

• Background:

– Airborne volcanic ash poses a significant risk to aircraft gas turbine

engines and can interrupt air travel resulting in revenue loss

– Limited understanding of the effect of low ash concentration level

encounters (previous volcanic ash engine testing conducted by Mike

Dunn (Calspan) evaluated much higher ash concentrations levels)

• VIPR3 VAE Goals:

– Introduce volcanic ash into the engine inlet to emulate engine ash

ingestion due to ash cloud encounters in flight

– Focus on low concentration levels (near the visually discernable

threshold)

– Characterize engine performance degradation due to ash ingestion

– Evaluate the capability of advanced engine health management

technologies for diagnosing volcanic ash induced engine degradation

• VIPR3 VAE Approach:

– Utilized Mazama ash in the 5 to 60 micron particle size range

– Exposed the engine to ash mass ingestion rates equivalent to ash

cloud encounters in the 1 to 10 mg/m3 concentration range

Spray nozzle configuration

for introduction of volcanic

ash into engine


www.nasa.gov

VIPR3 Volcanic Ash Environment (VAE)

Testing Overview

12

Video overview of VIPR3 Volcanic Ash

Environment (VAE) Test


www.nasa.gov

Summary

13

• Gas Path Diagnostic (GPD) Testing

– Model-Based Gas Path Diagnostic Architecture applied for

processing streaming (continuous) aircraft engine measurement

data and diagnosing bleed faults

• Volcanic Ash Environment (VAE) Testing

– Successfully introduced volcanic ash into engine

• Additional data analysis ongoing


www.nasa.gov

References

14

• Model-Based Diagnostic Architecture– Simon, D. L., (2010), “An Integrated Architecture for Onboard Aircraft Engine

Performance Trend Monitoring and Gas Path Fault Diagnostics,” Proceedings of The

2010 JANNAF Joint Subcommittee Meeting, Colorado Springs, CO, May 3-7.

– Armstrong, J.B., Simon, D.L., (2011), “Implementation of an Integrated On-Board Aircraft

Engine Diagnostic Architecture,” AIAA-2011-5859, 47th AIAA Joint Propulsion

Conference & Exhibit, San Diego, CA, July 31-August 3.

– Simon, D.L., (2012), “An Integrated Approach for Aircraft Engine Performance Estimation

and Fault Diagnostics,” ASME-GT2012-69905, 2012 ASME Turbo Expo, Copenhagen,

Denmark, June 11-15.

• Vehicle Integrated Propulsion Research (VIPR) Testing– Gary W. Hunter, John D. Lekki, Donald L Simon. “Development and Testing of Propulsion

Health Management,” Proceedings of the Workshop on Integrated Vehicle Health

Management and Aviation Safety; Bangalore, India; January 2012.

– Lekki, John D., Simon, Donald L., Hunter, Gary W., Woike, Mark, Tokars, Roger P.,

“Vehicle Integrated Propulsion Research for the Study of Health Management

Capabilities,” Turbine Engine Technology Symposium, September 2012, Dayton, OH.

Documents

Vehicle Integrated Propulsion Research (VIPR) Gas …...Engine Test Program 3 • VIPR is a series of ground-based on-wing engine demonstrations to mature aircraft engine health management